Rapid assembly lightweight modular structure

ABSTRACT

Disclosed is a lightweight modular structure that can be transported to the surface of an extraterrestrial mass in one rocket payload, and assembled rapidly by two robots. The structure is airtight, thermally insulated, resistant to micro-meteoroid penetration, includes an airlock, provides radiation shielding, and is capable of being pressurized and equipped with life support systems. The structure is designed to bear the exterior load of being buried under one to two meters of extraterrestrial material on extraterrestrial masses with gravity up to 40% of Earth&#39;s gravity, a configuration that can provide additional thermal insulation, additional radiation protection, and additional protection against micrometeoroid penetration. The structure can be assembled in different configurations, and may include one or more windows, and hangar-style doors at one or both ends to accommodate passage of large items. A plurality of these modular structures can be connected to each other utilizing an optional modular walkway. The structure can be used on extraterrestrial masses and on Earth for habitation, as a laboratory, as a greenhouse, and as a maintenance facility; it can be used on an extraterrestrial mass as a very large airlock, and it can be used on Earth as a biological/chemical warfare, or hazmat operations center or laboratory.

STATEMENT REGARDING FEDERALLY SPONSORED R&D

No government rights: the owner/inventor received no government funding or in-kind government support during the process of conceiving this invention, and no government contract, grant, SBIR, STTR, cost shared subcontract, CRADA, WFO, collaborative or cooperative agreement is related to this concept.

COPYRIGHTED MATERIAL

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to modular outer space structures, and more specifically to a lightweight modular structure that can be assembled rapidly and utilized for habitation and other purposes on the surface of extraterrestrial masses such as the Moon and Mars.

2. Description of the Prior Art

Historically assembly of structures in outer space has been a long, tedious, labor-intensive and expensive process, as demonstrated the International Space Station assembly process. Due to the many hours of arduous and complex activity necessary to assemble space structures in a vacuum, astronauts have faced a significant risk of accidental injury or death during assembly activities, particularly if their protective space suit is damaged.

Inexpensive, lightweight and portable structures' most significant period of development began in 1941 when the U.S. Government believed war was imminent and the U.S. military saw a need for lightweight portable structures. The government asked the George A. Fuller Company to design and produce a but to US specification. These huts became known as “Quonset huts”, and approximately 165,000 of the various versions of the design were built and sold to the U.S. government during World War II. (http://www.seabeesmuseum.com/Quonset_Huts.html)

In the years since World War II many designs for rapid assembly, lightweight, portable structures have been patented. Some examples are 6,594,958 to Melson et al., 6,131,343 to Jackson, Jr., 5,581,960 to Lewis, 5,333,421 to McKenna, 4,887,397 to Peterson, and 4,469,676 to Davey. These structures were not designed for rocket launching and use in outer space. These structures were not designed to fit in the payload faring of a launch vehicle when unassembled. These structures are not airtight, cannot be pressurized, and cannot be equipped with life support systems for use in outer space. These structures are not thermally insulated to maintain an interior temperature comfortable for humans when temperatures exterior to the structure are in the extreme range encountered in outer space. These structures do not provide occupants with any significant protection against solar/solar flare proton radiation and galactic cosmic radiation.

U.S. Pat. No. 5,086,999 to Mullen is an example of a rigid modular structure designed for use in outer space. This invention is composed primarily of metal, so its weight makes it expensive to launch, and it is not designed for use on the surface of extraterrestrial masses. This invention is designed to be transported in the cargo bay of a United States space shuttle. The United States no longer operates the space shuttle, so this invention is obsolete.

In recent years, U.S. company Bigelow Aerospace, LLC has demonstrated inflatable space structures with soft-shell exteriors made of generally pliable and flexible material. These structures do not require human assembly; they launch deflated and inflate after they reach orbit. Two separately-launched Bigelow inflatable modules are currently in low Earth orbit that did not require human assembly.

As currently conceived, inflatable structures cannot accommodate entry of large articles into the structure without significant modification and human assembly activity, they do not provide any significant protection against solar/solar flare proton radiation or galactic cosmic radiation (gamma rays), and they are not designed to bear external weight, as for example a structure might experience if it were buried under 1-2 meters of extraterrestrial material. Modular inflatable and expandable space structures are typified, for example, by U.S. Pat. No. 6,899,301 B2 to Bigelow, U.S. Pat. No. 6,439,508 to Taylor, U.S. Pat. No. 6,231,010 to Schneider, et al, U.S. Pat. No. 6,547,189 to Raboin, et al, and U.S. Pat. No. 5,086,999 to Mullen.

U.S. Pat. No. 7,469,864 to Bigelow describes a method of assembling a habitable structure comprised of a plurality of inflatable structures, connecting nodes, busses, and landing pads that are assembled in orbit, and subsequently landed on the surface of an extraterrestrial mass. This structure can be assembled robotically. This design is deficient because it risks structural deformation and degradation of structural integrity during the assembled structure's descent to the surface. The structure provides no significant radiation shielding, and is not designed for the external load that would result if the structure were buried under 1-2 meters of extraterrestrial material.

U.S. Pat. No. 6,899,301 to Bigelow describes a method for installing windows on an inflatable structure. This method requires activity outside of the structure to locate a bladder and template on the outer shell, to penetrate and cut the fabric of the outer shell following the template, and to install the window. This patent does not state that the method can be accomplished robotically, so human activity must be necessary. It follows that installation of hangar doors would require human assembly efforts outside the structure as well. Thus, this design poses a risk of injury or death of astronauts when astronauts work in the vacuum outside the facility to perform assembly work. This structural design can also take a significant amount of time to completely assemble if the structure were to include hangar doors and/or one or more windows.

SUMMARY OF THE INVENTION

The present invention relates to a lightweight modular structure that can be assembled rapidly and utilized for habitation and other purposes on the surface of extraterrestrial masses. The structure is airtight, thermally insulated, micro-meteoroid penetration resistant, includes an airlock, provides radiation shielding, and is capable of being pressurized and equipped with life support systems. The structure can be assembled in different configurations, and may include one or more windows, and hangar-style doors at one or both ends to accommodate passage of large items. A plurality of these modular structures can be connected to each other utilizing modular connecting elements.

A primary object of the present invention is to provide a modular structure that one or more robots can rapidly assemble on an extraterrestrial mass in advance of the first human mission, such that the structure can be immediately occupied by humans when they arrive.

Another object of the present invention is to provide a structure that is lighter in weight than other hard-shell habitation structures designed for use on extraterrestrial masses.

Another object of the present invention is to provide a structure that is modular, and designed to fit in the payload faring of a launch vehicle, such that the un-assembled structure can be delivered from Earth to an extraterrestrial mass in one payload.

Another object of the present invention is to provide a structure that is thermally insulated, such that the interior of the structure remains at a temperature that is comfortable for humans, for example 60°-80° F., while outside temperatures may range from −150° C./−238° F. to 120° C./248° F.

Another object of the present invention is to provide a structure that protects occupants against external solar/solar flare proton radiation and galactic cosmic radiation, such that the radiation dose-equivalents for each occupant do not exceed NASA's recommended limits for U.S. astronauts in low-Earth orbit.

Another object of the present invention is to provide a structure that can bear the exterior load of being buried under one to two meters of extraterrestrial material on extraterrestrial masses with gravity up to 40% of Earth's gravity.

Another object of the present invention is to provide a structure which is airtight at four to twenty psia.

Another object of the present invention is to provide a structure that is significantly lower in cost than other hard-shell habitation structures designed for use on extraterrestrial masses.

Another object of the present invention is to provide a structure that can accommodate up to 6 human inhabitants for up to one year.

Another object of the present invention is to provide a structure that can be connected with other structures to add additional habitable space as needed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of the structure exterior without the external thermal insulation layer installed, such that the seams between modular panels are visible.

FIG. 2 is a top section floor plan of the structure.

FIG. 3 is a front section view of the structure.

FIG. 4. is an interior view of a modular panel without the insulation and polymeric material layers attached.

FIG. 5 is a side view of a modular panel with the polymeric material layer and insulation layers shown.

DETAILED DESCRIPTION OF THE INVENTION 1. Definitions

NASA radiation dose-equivalent limits recommended for U.S. astronauts in low Earth orbit:

Exposure Time Vital Organ, Rem Occular, Rem Skin, Rem Career 100-400* 400 600 Annual 50 200 300 30 Days 25 100 150 (Ref. NASA Technical Paper 309, Radiation Protection for Human Missions to the Moon and Mars, at p. 2 (1991))

2. Best Mode of the Invention

FIG. 1 shows an exterior isometric view of the best mode contemplated by the inventor of the rapid assembly lightweight modular structure 10 utilized as a habitation facility according to the concepts of the present invention.

3. How to Make the Invention

As shown in FIG. 1 the structure is comprised of modular composite panels 2, an airlock unit 4, one set of composite hangar doors comprised of four door panels 6, and one window 8. An optional connecting walkway structure 12 permits a plurality of these structures to be connected together to provide additional habitable space.

As shown in FIG. 2 interior rafters 14 and composite panels adhesively attached to the top of the rafters 16 can support air-handling ducts 18, and stored items. A preferred material for the rafters would be Brockwell Structure Technology, composite structural material with enhanced load bearing capacity per unit mass, U.S. Pat. Application No. 20120225237. Electrical connectors, electrical wiring, and electric outlets can be embedded in rafters constructed of Brockwell composite.

As shown in FIG. 3 at the rear of the structure a conventional terrestrial interior door 20 leads to a lavatory area 22 which can be equipped with a cabinet with two sinks and faucets 24, two shower enclosures 26 and a toilet 28.

An interior door at the right of the lavatory 30 leads to a utility room 32 which provides space for pressurized air tanks 34, a water tank 36, and life support systems 38 sufficient to support habitation of the structure by six human beings.

Countertops are mounted in the structure interior along the opposite side of the wall where the air, water, and life support systems are located 40, and along the right wall of the structure 42. If these countertops 40 and 42 do not have sinks, Bunsen burners, cabinets or other equipment installed on them, they can be folded down parallel to the walls when not in use.

As shown in FIG. 4 sealing means comprised of polymeric material 44 is adhesively installed over the mating surfaces of the exterior composite panels 2. As shown in FIG. 1, the polymeric material 44 also adhesively seals the mating surfaces between composite panels 2 and: the airlock 4, the hangar doors 6, and the window 8, thus forming an airtight seal about the enclosed interior volume.

The composite panels are mechanically joined across mating seams by attachment mechanisms 46 which are simply shown as rectangles to identify the location where they are mounted on the panel. These attachment mechanisms will be selected from the group consisting of bonded flanges and screws; threaded inserts and screws; composite cross members and screws; hinges; and clamps.

As shown on FIG. 5, after the structure is assembled a layer of polymeric material 48, for example methyl methacrylate/ethyl acrylate copolymer, is adhesively attached to the inner surface of the modular exterior panels 2 and other exterior parts to provide a secondary seal about the enclosed interior volume, thus ensuring that the structure remains airtight. The structure can be pressurized to 14.7 psia.

When the thermal insulation blanket 50 is affixed to the exterior of the assembled structure 10, the interior temperature will remain stable at approximately 70° F. The insulation layer will be multilayer insulation or some other type of insulation.

The assembled structure 10 with thermal insulation blanket 50 installed provides radiation shielding sufficient to ensure that occupants can inhabit the structure for one year without exceeding NASA's recommended radiation exposure limits for U.S. astronauts in low Earth orbit. A preferred material for radiation shielding would be the High Hydrogen Content Nanostructured Polymer Radiation Protection System under development at the University of Houston pursuant to NASA's Space Technology Research Grants Program (Ref. NASA Selects Early Stage Innovation Proposals From 10 Universities, NASA Press Release 12-373, Oct. 24, 2012; http://www.nasa.gov/directorates/spactech/strg/2012_stro_esi_ignatiev.html; http://www.nasa.gov/pdf/709702main_ignatiev_update.pdt). This material is suitable for use in structural elements, so it can be used as a constituent element of the exterior composite panels and other elements of the structure.

4. How to Use the Invention

The assembled structure can be used as a habitation structure as can be amply seen from the drawings. The structure is primarily comprised of composite material that is lighter in weight than comparable prior designs for Moon and Mars habitats, which are primarily comprised of metal. The structure is modular and can be assembled in many configurations. The structure provides significant solar/solar flare proton radiation and galactic cosmic radiation protection for human occupants. The structure is thermally insulated to maintain a moderate temperature that is safe and comfortable for humans. The structure is airtight, can be pressurized, and can be equipped with life support equipment suitable for human habitation.

The unassembled modular elements can be delivered to the structure's destination in one rocket-launched payload, and the structure can be assembled by robots prior to the arrival of the first human mission.

The assembled structure can be equipped and used as a greenhouse, with lighting suitable for growing plants suspended from the rafters, and hydroponic equipment installed on, below and around the countertops and folding tables that can be set up in the interior of the structure.

The assembled structure can be equipped and used as a laboratory, with sinks and Bunsen burners installed on the countertops, cabinets on and above the countertops, and laboratory benches and equipment installed in the interior of the structure.

The assembled structure can be equipped for use as a maintenance facility for rovers, and excavation, construction, mining and other equipment. Due to the abrasive nature of lunar dust, one can anticipate that equipment operated on the lunar surface will require frequent maintenance and periodic repair in order to remain operational.

The structure can function as a very large airlock when an air compressor is installed in the utility area 9, and the structure is equipped with hangar doors 6 at both ends. This configuration would be useful to allow large items such as excavation equipment to pass from unpressurized vacuum to a pressurized construction or mining area underground, for example at the entrance to a lava tube or cave.

The structure can be buried under one to two meters of extraterrestrial material, to increase thermal insulation, radiation protection and micrometeoroid impact protection. The process of burying the structure with extraterrestrial material can be accomplished robotically.

An optional layer comprised of a plurality of layers of fabric selected from the group consisting of Nextel, Kevlar, Nomex, and fabrics with similar properties, alternated with a dense polymer or copolymer foam, can be installed robotically on the outside of the assembled structure between the composite panels 2 and the thermal blanket 50 to provide additional micrometeoroid impact protection. In most cases, assembling the structure in an excavated trench, or with its rear wall abutted against a crater wall, lava tube or cave, and then burying the structure in extraterrestrial material is a less expensive and time consuming manner of providing additional impact protection. However, in some circumstances, for example if the structure is assembled on a lava flow where extraterrestrial material is not easily excavated, the additional time and expense of installing this protective layer can be justified. Design of this protective layer would be based upon NASA's design of the Transhab facility, and consideration of new materials not available when Transhab was designed. (Ref. http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20110000798_(—)2010047135.pdf)

Military and civilian authorities can use the structure on Earth as a command post or detection laboratory in an area subject to chemical or biological warfare, when the structure is pressurized, and equipped with chemical and/or biological detection and decontamination equipment. Similarly, hazmat teams can use the structure in the event of a major contamination incident such as an explosion at a chemical factory, or a train derailment.

Oil & gas and mining companies can use the structure with its thermal blanket 50 installed in arctic areas where they are conducting exploration, drilling and mining activities. The structure's rapid assembly, versatility of use, large equipment access, and thermal insulation capabilities should make the structure quite useful for these companies.

The same capabilities that make the structure useful for oil & gas and mining companies in the arctic will also make the structure useful for scientific teams at bases in the Antarctic-rapid assembly, versatility, large equipment access, and thermal insulation.

5. Examples of the Invention

Thus it will be appreciated by those skilled in the art that the present invention is not restricted to the particular best mode embodiments described with reference to the drawings, and that variations may be made therein without departing from the scope of the present invention as defined in the appended claims and equivalents thereof. 

What is claimed is:
 1. A rapid assembly lightweight modular structure, comprising: modular elements that when assembled form a structure that is airtight from four to twenty psia, including composite panels; an airlock unit; one set of hangar doors; a window; two interior doors; two countertops; composite rafters; electrical connectors, wiring and electrical outlets; a toilet; cabinet; two bathroom sinks with faucets; two shower enclosures; water tank; plumbing; kitchen sink with faucet; compressed air tank; life support equipment; air-handling ductwork; polymeric sealing material; attachment mechanisms; and adhesive.
 2. A rapid assembly lightweight modular structure according to claim 1, wherein said structure is designed to be launched from Earth to an extraterrestrial mass, unassembled, in one rocket launch payload, and then assembled on the surface of the extraterrestrial mass by two robots, such that the structure is ready to be inhabited when humans arrive.
 3. A rapid assembly lightweight modular structure according to claim 1, wherein said structure includes a modular walkway that can connect the structure to another structure to provide additional living space.
 4. A rapid assembly lightweight modular structure according to claim 1, wherein a thermal blanket is affixed to the exterior of the structure such that the interior of the structure remains at a temperature that is comfortable for humans, for example 60°-80° F., while outside temperatures may range from −150° C./−238° F. to 120° C./248° F.
 5. A rapid assembly lightweight modular structure according to claim 1, wherein the assembled structure with thermal insulation blanket installed provides radiation shielding sufficient to ensure that all occupants can inhabit the structure for one year without exceeding NASA's recommended radiation exposure limits for U.S. astronauts in low Earth orbit.
 6. A rapid assembly lightweight modular structure according to claim 1, wherein said structure is designed to bear the weight of an exterior load on extraterrestrial masses with gravity up to 40% of Earth's gravity, and wherein the structure is buried under one to two meters of extraterrestrial material on all sides except the front of the structure, to provide additional thermal insulation, additional radiation protection, and additional protection against micrometeoroid penetration.
 7. A rapid assembly lightweight modular structure according to claim 1, wherein an optional layer comprised of a plurality of layers of fabric selected from the group consisting of Nextel, Kevlar, Nomex, and fabrics with similar properties, alternated with a dense polymer or copolymer foam, can be installed robotically on the outside of the assembled structure between the composite panels 2 and the thermal insulation layer 50 to provide additional micrometeoroid impact protection.
 8. A rapid assembly lightweight modular structure according to claim 1, wherein said structure is equipped and used as a greenhouse, with lighting suitable for growing plants suspended from the rafters; and hydroponic equipment installed on, under and around countertops, and on, under and around folding tables that are set up in the interior of the structure.
 9. A rapid assembly lightweight modular structure according to claim 1, wherein said structure is equipped and used as a laboratory, with sinks and Bunsen burners installed on the countertops; cabinets installed under and above the countertops; and laboratory benches and equipment installed in the interior of the structure.
 10. A rapid assembly lightweight modular structure according to claim 1, wherein said structure is equipped for use as a maintenance facility for rovers; excavation equipment; construction equipment; and mining and other equipment.
 11. A rapid assembly lightweight modular structure equipped to function as a very large airlock, comprising: modular elements that when assembled form a structure that is airtight from four to twenty psia, including composite panels; an airlock unit; two sets of hangar doors, one at each end of the structure; composite rafters; electrical connectors, wiring and electrical outlets; air compressor, compressed air tank; life support equipment; air-handling ductwork; polymeric sealing material; attachment mechanisms; adhesive; and a thermal blanket, such that large items such as excavation equipment can pass from unpressurized vacuum into the structure, and then after the structure is sealed and pressurized, can pass through the rear hangar doors into a pressurized construction or mining area underground, for example at the entrance to a lava tube or cave.
 12. A rapid assembly lightweight modular structure equipped for use on Earth, comprising: modular elements that when assembled form a structure, including composite panels; a window; two interior doors; two countertops; composite rafters; electrical connectors, wiring and electrical outlets; a toilet; cabinet; two bathroom sinks with faucets; two shower enclosures; water tank; plumbing; kitchen sink with faucet; a furnace, air-handling ductwork; polymeric sealing material; attachment mechanisms; and adhesive.
 13. A rapid assembly lightweight modular structure according to claim 11, wherein said structure is airtight from four to twenty psia and includes a compressed air tank; life support equipment; an airlock unit; chemical and/or biological detection and decontamination equipment, such that military and civilian authorities can use the structure as a command post or detection laboratory in an area subject to chemical or biological warfare, or hazmat teams can use it in the vicinity of a major contamination incident such as an explosion at a chemical factory, or a train derailment.
 14. A rapid assembly lightweight modular structure according to claim 11, wherein said structure includes a thermal blanket or other insulation such that the structure can be used by oil & gas, and mining companies in arctic areas where they are conducting exploration, drilling and mining activities; and by scientific teams at bases in the Antarctic, for use as a habitation facility; a laboratory; a greenhouse; or a maintenance/garage facility. 